CAME GGT80 Installation guide

Brand: CAME

Model: GGT80

Type: Installation guide

Automatic road barriers

GGT80AGS GGT80RGS GGT80ACS

GGT80AX4 GGT80AX6

INSTALLATION MANUAL

FA01918-EN

English

DEVICE MANUAL RELEASE

Releasing the device may be dangerous for the user, if the boom fastening has been damaged or if the boom is no longer intact, as the result of an accident or

installation error.

In these cases, the tensioned springs no longer guarantee that the boom is balanced. The boom may suddenly rotate when being released.

Manual release may cause the operator to move in an uncontrolled manner due to a mechanical fault or an imbalance.

With the gearmotor released, the operator does not work.

The balance springs must not be tensioned (boom vertical) when performing maintenance on the barrier.

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GENERAL PRECAUTIONS FOR INSTALLERS

Important safety instructions.

Please follow all of these instructions. Improper installation may cause serious bodily harm.

Before continuing, please also read the general precautions for users.

Only use this product for its intended purpose. Any other use is hazardous. • The manufacturer cannot be held liable for any

damage caused by improper, unreasonable or erroneous use. • This product is defined by the Machinery Directive (2006/42/EC)

as partly completed machinery. • Partly completed machinery means an assembly which is almost machinery but which cannot

in itself perform a specific application. • Partly completed machinery is only intended to be incorporated into or assembled with

other machinery or other partly completed machinery or equipment thereby forming machinery to which the Machinery Directive

(2006/42/EC) applies. • The final installation must comply with the Machinery Directive (2006/42/EC) and the European reference

standards in force. • The manufacturer declines any liability for using non-original products, which would also void the warranty.

• All operations indicated in this manual must be carried out exclusively by skilled and qualified personnel and in full compliance

with the regulations in force. • The device must be installed, wired, connected and tested according to good professional practice,

in compliance with the standards and laws in force. • Make sure the mains power supply is disconnected during all installation

procedures. • Check that the temperature ranges given are suitable for the installation site. • Make sure that opening the automatic

barrier does not constitute a hazard. • Do not install on slopes i.e. any surfaces that are not perfectly level. • Do not install the

operator on surfaces that could yield and bend. If necessary, add suitable reinforcements to the anchoring points. • Make sure

that no direct jets of water can wet the product at the installation site (sprinklers, water cleaners, etc.). • Make sure you have set

up a suitable dual-pole cut-off device along the power supply that is compliant with the installation rules. It should completely cut

off the power supply according to category III surcharge conditions. • Demarcate the entire site properly to prevent unauthorised

personnel from entering, especially minors. • In case of manual handling, have one person for every 20 kg that needs hoisting;

for non-manual handling, use proper hoisting equipment in safe conditions. • When the operator is being fixed in place, it may be

unstable and overturn. Be careful and do not lean on it until it is fully fastened in place. • Use suitable protection to prevent any

mechanical hazards due to persons loitering within the operating range of the operator. • The electrical cables must pass through

special pipes, ducts and cable glands in order to guarantee adequate protection against mechanical damage. • Make sure that the

moving mechanical parts are suitably far away from the wiring. • The electrical cables must not touch any parts that may overheat

during use (such as the motor and transformer). • All fixed controls must be clearly visible after installation, in a position that allows

the guided part to be directly visible, but far away from moving parts. In the case of a hold-to-run control, this must be installed at

a minimum height of 1.5 m from the ground and must not be accessible to the public. • If the passage is wider than 3 m, you must

use a fixed support for the boom. • If not already present, apply a permanent tag that describes how to use the manual release

mechanism close to it. • Make sure that the operator has been properly adjusted and that the safety and protection devices and the

manual release are working properly. • Before handing over to the final user, check that the system complies with the harmonised

standards and the essential requirements of the Machinery Directive (2006/42/EC). • Any residual risks must be indicated clearly

with proper signage affixed in visible areas, and explained to end users. • Put the machine’s ID plate in a visible place when the

installation is complete. • If the power supply cable is damaged, it must be immediately replaced by the manufacturer or by an

authorised technical assistance centre, or in any case, by qualified staff, to prevent any risk. • Keep this manual inside the technical

folder along with the manuals of all the other devices used for your automation system. • Make sure to hand over to the end user

all the operating manuals of the products that make up the final machinery. • The product, in its original packaging supplied by

the manufacturer, must only be transported in a closed environment (railway carriage, containers, closed vehicles). • If the product

malfunctions, stop using it and contact an authorised support centre.

The manufacture date is provided in the production batch printed on the product label. If necessary, contact us at https://www.

came.com/global/en/contact-us.

The general conditions of sale are given in the official CAME price lists.

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Main points of danger for people

Risk of trapping hands.

No transiting.

DISMANTLING AND DISPOSAL

CAME S.p.A. employs an Environmental Management System at its premises. This system is certified and compliant with the UNI EN ISO 14001 standard to ensure

that the environment is respected and safeguarded. Please continue safeguarding the environment. At CAME we consider it one of the fundamentals of our operating and

market strategies. Simply follow these brief disposal guidelines:

DISPOSING OF THE PACKAGING

The packaging materials (cardboard, plastic, etc.) can be disposed of easily as solid urban waste, separated for recycling.

Before dismantling and disposing of the product, please always check the local laws in force.

DISPOSE OF THE PRODUCT RESPONSIBLY.

DISPOSING OF THE PRODUCT

Our products are made of various materials. Most of these materials (aluminium, plastic, iron and electrical cables) are classified as solid urban waste. They can be

separated for recycling and disposed of at authorised waste treatment plants.

Other components (electronic boards, transmitter batteries, etc.) may contain pollutants.

These must be removed and disposed of by an authorised waste disposal and recycling firm.

It is always advisable to check the specific laws that apply in your area.

DISPOSE OF THE PRODUCT RESPONSIBLY.

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PRODUCT DATA AND INFORMATION

Key

This symbol shows which parts to read carefully.

This symbol shows which parts describe safety issues.

This symbol shows what to tell users.

The measurements, unless otherwise stated, are in millimetres.

Description

803BB-0180

GGT80AGS - Automatic barrier with irreversible gearmotor 24 V DC with encoder; painted galvanised steel cabinet; accessories available. Balance springs included.

803BB-0220

GGT80RGS - Automatic barrier with irreversible gearmotor 24 V DC with encoder; painted galvanised steel cabinet; accessories available. Balance springs included.

803BB-0250

GGT80AX4 - Automatic barrier with irreversible gearmotor 24 V DC with encoder; satin-finish AISI 304 steel cabinet; accessories available. Balance springs included.

803BB-0270

GGT80AX6 - Automatic barrier with irreversible gearmotor 24 V DC with encoder; satin-finish AISI 316 steel cabinet; accessories available. Balance springs included.

803BB-0290

GGT80ACS - Automatic barrier with irreversible gearmotor 24 V DC with encoder; custom-RAL painted galvanised steel cabinet; accessories available. Balance springs

included.

Intended use

Ideal solution for apartment blocks and industrial applications

Any installation and/or use other than that specified in this manual is forbidden.

Usage limitations

MODELS GGT80AGS GGT80RGS GGT80AX4 GGT80AX6 GGT80ACS

Max. net clearance width (m) 7,8 7,8 7,8 7,8 7,8

Technical data

MODELS GGT80AGS GGT80RGS GGT80AX4 GGT80AX6 GGT80ACS

Power supply (V - 50/60 Hz) 230 AC 120 AC 230 AC 230 AC 230 AC

Maximum current draw (A) 1,1 2,2 1,1 1,1 1,1

Motor power supply (V) 24 DC 24 DC 24 DC 24 DC 24 DC

Standby consumption (W) 77777

Power (W) 300 300 300 300 300

Colour 7024 7024 - - RAL X

Operating temperature (°C) -20 ÷ +55

(-40 with item

001PSRT01)

-20 to +55 (-40 with

item 001PSRT01)

-20 ÷ +55

(-40 with item

001PSRT01)

-20 ÷ +55

(-40 with item

001PSRT01)

-20 ÷ +55

(-40 with item

001PSRT01)

Torque (Nm) 600 600 600 600 600

Opening time at 90° (s) 4 ÷ 8 4 ÷ 8 4 ÷ 8 4 ÷ 8 4 ÷ 8

Cycles/hour 160 160 160 160 160

Cycles/day 2500 2500 2500 2500 2500

Protection rating (IP) 54 54 54 54 54

Insulation class IIIII

Weight (kg) 90 90 90 90 90

Storage temperature (°C)* -20 ÷ +70 -20 ÷ +70 -20 ÷ +70 -20 ÷ +70 -20 ÷ +70

Average life (cycles)** 3.000.000 3.000.000 3.000.000 3.000.000 3.000.000

(*) Before installing the product, keep it at room temperature where it has previously been stored or transported at a very high or very low temperature.

(**) The average product life specified should be understood purely as an indicative estimate. It applies to normal usage conditions and where the product has been

installed and maintained in compliance with the instructions provided in the CAME technical manual. The average product life is also affected, including significantly,

by other variables such as, but not limited to, climatic and environmental conditions. The average product life should not be confused with the product warranty.

Fuse table

MODELS GGT80AGS GGT80RGS GGT80AX4 GGT80AX6 GGT80ACS

Line fuse 1.6 A-F 3.15 A-F 1.6 A-F 1.6 A-F 1.6 A-F

Accessory fuse 2 A-F 2 A-F 2 A-F 2 A-F 2 A-F

Control board fuse 4 A-F 4 A-F 4 A-F 4 A-F 4 A-F

Motor fuse 10 A-F 10 A-F 10 A-F 10 A-F 10 A-F

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Description of parts

Barrier

Cover

Boom anchoring plate

Intermediate plate

Fastening flange

Anti-shearing cover

Photocell holes

Lock for release

Cabinet

Inspection hatch

Inspection-hatch lock

Control panel

Safety microswitch with cover open

Mechanical stop for the boom adjustment

Lever arm

Gear motor with encoder

Auxiliary

Line fuse

Power supply terminal block

Anchoring plate

Anchoring bracket

Boom profile end cap

Spring anchoring pin

001G06080 - Balance spring Ø 55 mm.

Released gearmotor safety microswitch

DIN rail

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Control board

Programming buttons

Terminal board for motor power supply

Display

Connector for plug-in radio frequency card (AF)

Terminal board for connecting the antenna

Terminal board for BUS accessories

Connector for the R700 or R800 decoding card

RSE_1 connector for RSE card

Terminal board for connecting the keypad selector

Terminal board for connecting the transponder selector switch

Terminal board associated with the RSE_1 connector for paired, alternate or

CRP connection

Terminal board associated with the RSE_2 connector for CRP connection, IO

485 card or Modbus RTU interface

Terminal board for connecting the electric lock

Terminal board for connecting the safety microswitch with cover open and

gearmotor released (NC contact)

RSE_2 connector for RSE card

Terminal board for connecting the warning LED strip

Terminal board for connecting control and safety devices

Terminal board for connecting the encoder

Accessories fuse

Terminal board for barrier status*

Control board fuse

Terminal board for power supply to the control board

Motor fuse

Connector for CAME KEY

Memory Roll card connector

* Only for ZL392 boards, version B

S1 GND

A B GND

EB EB

024

+E -

017

TAMPER

BUS

10 11 E1 TS 1 2 3 3P 4 5 7 2 CX CY CZ +RG

FCA CM1 FCC CM2

16 151718

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Size

482

1222

913

max. 7800 381

249

116

416

Cable types and minimum thicknesses

Cable length (m) up to 20 from 20 to 30

Power supply 230 V AC 3G x 1.5 mm² 3G x 2.5 mm²

Power supply 120 V AC 3G x 1.5 mm² 3G x 2.5 mm²

24 V AC/DC flashing beacon 2 x 1 mm² 2 x 1 mm²

TX Photocells 2 x 0.5 mm² 2 x 0.5 mm²

RX photocells 4 x 0.5 mm² 4 x 0.5 mm²

24 V DC electric lock 2 x 1 mm² 2 x 1 mm²

Command and control devices *no. x 0.5 mm² *no. x 0.5 mm²

* no. = see product assembly instructions - Warning: the cable cross-section is indicative and varies according to the motor power and cable length.

To connect the antenna, use RG58 cable (up to 5 m).

For installation in an outdoor environment, use cables with properties at least equivalent to those of type H05RN-F (with designation 60245 IEC 57).

For installation in an indoor environment, use cables with properties at least equivalent to those of type H05VV-F (designation to 60227 IEC 53).

If the cable lengths differ from those specified in the table, define the cable cross-sections according to the actual power draw of the connected devices and in

line with regulation CEI EN 60204-1.

For multiple, sequential loads along the same line, recalculate the values in the table according to the actual power draw and distances. For information on

connecting products not covered in this manual, please see the documentation accompanying the products themselves.

For paired and CRP connection, use a UTP CAT5 cable. Maximum length 1000 metres.

Single branch length (m) max. 50 m

BUS cable 2 x 1 mm²

The total length of all branches can be a maximum of 150 m.

The cable cannot be shielded.

Wind resistance

The table shows the boom wind-load resistance.

The value relates to the boom only and does not refer to any applicable accessories.

Resistance class with reference to the EN 13241 standard.

Type Boom 4.4 m Boom 6.4 m Boom 8 m

Resistance class 4 3 2

Wind pressure [Pa] 1100 600 400

Maximum wind speed [km/h] 160 120 100

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INSTALLATION

The following illustrations are examples only. The space available for fitting the operator and accessories varies depending on the area where it is installed. It is

up to the installer to find the most suitable solution.

In case of manual handling, have one person for every 20 kg that needs hoisting; for non-manual handling, use proper hoisting equipment in safe conditions.

When the operator is being fixed in place, it may be unstable and overturn. Be careful and do not lean on it until it is fully fastened in place.

Preliminary operations

If the flooring does not allow the device to be fastened in a solid and stable way, lay a cement slab.

Dig a hole for the foundation frame.

Set up the corrugated tubes needed for the wiring coming out of the junction pit.

The number of tubes depends on the type of system and the accessories that are going to be fitted.

460

240

380

140

500

600

400

Laying the anchoring plate

Set up a foundation frame that is larger than the anchoring plate.

Fit an iron cage in the foundation frame to reinforce the concrete.

Assemble the anchoring braces to the plate.

Fit the anchoring plate in the iron cage.

The tubes must pass through the existing holes.

Cast cement into the foundation frame.

The plate must be perfectly level and the screw threads completely above surface.

Wait at least 24 hours for the cement to dry.

Remove the foundation frame.

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Fill the hole with soil around the concrete block.

Remove the nuts from the screws.

Thread the electrical cables into the tubes so that they protrude by about 1500 mm.

Preparing the barrier

With the inspection hatch open, the operator does not work.

Fastening the barrier

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Changing the boom opening direction

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Boom installation

Insert the reinforcement inside the boom.

Fix the flange and the intermediate plate to the boom.

First install the LED strip (where applicable), ONLY THEN fix the flange and the intermediate plate.

Tighten the screws using a torque wrench and a torque of 20 Nm.

Fix the boom to the anchoring plate.

Tighten the screws using a torque wrench and a torque of 20 Nm.

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Cut the slot-cover profiles to the same size as the boom slot minus 10 millimetres.

Insert the slot-cover profiles into the grooves on both sides of the boom.

Insert the anti-impact rubber profile into the groove.

Cut off the excess part of the profile.

Use the screws to fasten the boom end cap.

Fit the anti-shearing protective cover onto the boom-attachment cover and fasten it using the screws supplied.

Choosing the hole for fixing the balance spring

Passage width clearance (m) 4,00 < 4,50 4,50 < 5,00 5,00 < 5,50 5,50 < 6,00 6,00 < 6,50 6,50 < 7,00 7,00 < 7,80

Boom with LED strip

A A B A A A A A A B B

Boom with LED strip and single skirt*

B A A A A B B B B B B

Boom with LED strip and full-height skirt

A A A A B B B B

---

Boom with LED strip and swing rest

A B A A A A A A A A

Boom with LED strip, single skirt and swing rest

A A A A A A

----

Boom with LED strip, full-height skirt and swing rest

A A B B B B

----

Simple boom means the boom complete with slot cover, cap and rubber profile.

If the passage is wider than 4 m, you must use a support for the boom (fixed or mobile).

Single skirt (803XA-0340):

- max 2 modules for a 4 metre boom

- max 3 modules for a 6 metre boom

- max 4 modules for up to a 7 metre boom

Full-height skirt (803XA-0350):

- max 2 modules for a 4 metre boom.

- max 3 modules for a 6 metre boom.

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Assembling the balance spring

Hex-head screw M12 x 120

Top spring attachment

Bushing Ø13.8

Washer M8

Hex-head screw M8 x 45

Bushing Ø19

M8 self-locking nut

M12 nut

Release the gearmotor.

Position the boom vertically.

Lock the gearmotor

456

Assemble the anchoring pin and fix it on the lever arm.

Tighten the eyelet tie rod to the lower part of the spring.

Screw the spring to the anchoring pin.

Hook the eyelet rod onto the anchoring bracket.

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Lubricate the spring when it is fully extended.

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Balancing the boom

Release the gearmotor.

Manually turn the spring to increase or reduce the traction. The boom should

stabilise at 45°.

Where there are two springs, carry out the procedure on both springs at the

same time.

Fasten the locknut.

Position the boom vertically.

Lock the gearmotor

Check the proper working state of the spring. When the boom is vertical, the

spring is not taut. When the boom is horizontal, the spring is taut.

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Determining the travel end points with mechanical limit switches

Check that the boom is parallel to the road surface when it is in the closed position and at about 89° when it is in the open position.

Correct the boom’s horizontal position

Release the gearmotor.

Open the inspection hatch.

Turn the mechanical stop until you reach the desired boom position.

Fasten the mechanical stop with a locknut.

Lock the gearmotor

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Correct the boom’s vertical position

Release the gearmotor.

Open the inspection hatch.

Turn the mechanical stop until you reach the desired boom position.

Fasten the mechanical stop with a locknut.

Lock the gearmotor

~1°

~89°

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ELECTRICAL CONNECTIONS

Passing the electrical cables

The electrical cables must not touch any parts that may overheat during use (such as the motor and transformer).

Make sure that the moving mechanical parts are suitably far away from the wiring.

Power supply

Make sure the mains power supply is disconnected during all installation procedures.

Before working on the control panel, disconnect the mains power supply and remove the batteries, if any.

Connecting to the electrical network

Line fuse

Phase

Neutral

Earth

Ferrite

Apply the ferrite supplied to the power supply cable.

Ferrite type p.n. ECQK922091.

The cable must pass through the ferrite twice (2 turns).

230 V AC

50/60 Hz

Power supply output for accessories

The output normally delivers 24 V AC.

10 11 E1 TS 1 2

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Maximum capacity of contacts

The total power of the outputs listed below must not exceed the maximum output power [Accessories]

Device Output Power supply (V) Power (W)

Accessories 10 - 11 24 AC 40

Additional light 10 - E1 24 AC 25

Flashing beacon 10 - E1 24 AC 25

Operator status warning light 10 - 5 24 AC 3

LED strip +RG 24 DC 12

The outputs deliver 24 V DC when the batteries start operating, if they are installed.

Device Output Power supply (V) Power (W)

BUS CXN BUS 15 DC 15

Only connect CAME devices with CXN BUS system